Process for making decorative tile mats



June 8, 1954 A. DRATLER PROCESS FOR MAKING DECORATIVE TILE MATS FiledFeb. 26, 1953 INVENTOR. ALBERT DRATLER BY a I QAIJM HIS ATTORNEYPatented June 8, 1954 UNITED STATES ATENT OFFICE PROCESS FOR MAKINGDECORATIVE TILE MATS 3 Claims.

This invention relates to a process for making decorative tile mats andconstitutes an improvement in the process disclosed in my co-pendingapplication, Serial No. 142,659, filed February 6, 1950, in the UnitedStates Patent Office.

The tile mats to which my process has specificapplication have the tilesthereon arranged in mosaic patterns, and are adapted by virtue of theirflexible backings for installation on walls, ceilings, floors orarchitectural surfaces of like character. These mats, or panels, areconventionally installed with their marginal edges forming complementaryjointing with adjacent panels to produce an over-all pattern of pleasingappear ance.

The individual tiles may be of glass, ceramics, plastics or othermaterial suitable for the purpose herein described.

An object of the invention is to provide a process for making mosaictile mats which will be simple and economical in practice and capable ofefi'icient and ready application to the production in quantity of matsof the desired motifs in design.

Other advantages of the invention will be discernible from the detaileddescription of my process hereinafter set forth.

In the accompanying drawing, the isometric views illustrate successivephases in the construction of the mats according to the steps of myprocess, like reference numerals designating identical parts throughoutthe several views which are:

Fig. 1, a panel marked with score lines for cutting into a first seriesof strips;

Fig.' 2, the panel arranged for spacing the strips with score linesmarked thereon defining a second series of rows;

Fig. 3, one of the rows of articulated tiles;

Fig. 4, the rows arranged for spacing preparatory to forming thefinished panel; and

Fig. 5, a fragmentary view of the finished panel.

The tile mat is formed from a single rectangular sheet or panel P (Fig.1), of material suitable for the individual tiles. The panel is firstout along parallel score lines I into a first series of variable widthstrips 2, each strip being of a different width from the strip nextadjacent thereto.

The panel is now arranged face downward upon a reference grid B (Fig.2), which is established from a block having a plurality of parallel,upstanding spacer members 3 defining a corresponding plurality ofchannels along which the strips 2 may be located to predetermine themarginal jointing spacings 4 intermediate the strips 2.

With the strips 2 thus located (Fig. 2), an intermediate flexiblebacking is united to the back faces of the strips, using any suitableadhesive for this purpose known in the art.

The panel, now consisting of articulated strips 2 and the intermediatebacking 5 applied thereto, is cut a second time along parallel scorelines 6 running cross-wise of the strips, thus producing a second seriesof rows 1. The score lines 6 are equi-spaced and the rows 1 each form analinement of articulated tiles 8, Fig. 3, held therein by the portion ofintermediate backing thereto attached.

A second reference grid B is established having a series of upstandingspacer members 9, dividing the grid into a corresponding series ofchannels according to which the rows 1 are now located. To effectstaggered relation between the side marginal edges of the tiles in onerow relative to those in the next adjacent rows, the alternate rows arereversed, end-for-end with their back faces up, and are thus locatedaccording to the reference grid B.

A primary backing, preferably of flexible material, !0, is now appliedover the rows 7 (Fig. 4), using any suitable adhesive known in the art.

It will be seen that the use of reference grids according to which thefirst series strips and the second series rows are located in thefinished mat will permit the arrangement within a single mat of rowsbearing tiles out of different original sheets or panels, since thegrids assure uniform spacing and widths in the respective strips androws from the original sheets. Thus, the finished mat may include tilesof variegated hues and colors to produce a mosaic Work of pleasingappearance and harmonious color blending.

The intermediate backing 5 may, if desired, be formed from a reticulatedfabric or open-mesh structure, such as buckram or the like, whereby anintimate bonding of the back faces of the tiles may be elfected to theprimary backing l0, as will be understood.

The invention is thus seen to provide a unique process for theproduction of decorative tile mats to meet the objects hereinabove setforth.

Having thus described the invention and the mode of its practice, what Iclaim as new and desire to secure by Letters Patent, is:

l. The process of making a decorative tile mat which COIlSiSts ofcutting a tile-forming single panel into a first series ofvariable-width parallel strips, spreading said series to space thestrips marginally therebetween, uniting a flexible intermediate backingto the back face of the cut up panel, cutting the backed-up panelcrosswise of the strips into a second series of articulated tile-bearingrows, reversing alternate rows end for end to effect staggered relationof the side marginal joints between the tiles of adjacent rows,spreading the second series to space the rows therein in parallelrelation, and applying a main flexible backing to the tile assembly thusformed.

2. The process of making a decorative tile mat which comprises the stepsof establishing a variable-width strip-spacing reference grid, cutting asingle rectangular panel into a first series strips, locating said firstseries strips in a horizontal plane according to the spacings of saidvariable-width grid, uniting said first series by an intermediatebacking of flexible fabric applied to the back face thereof,establishing an equalwidth strip-spacing reference grid, cutting theunited first series cross-wise of the strips therein into a secondseries of articulated tilebearing rows, locating the rows according tothe spacings of said equal-width reference grid with alternate rowsreversed end for end to effect a staggered relation between the sidemarginal joints intermediate the tiles of adjacent rows, said rows beingarranged in a common horizontal plane with their intermediate backingup, and uniting said rows by a flexible primary backing applied to theback faces thereof,

3. The process of making a decorative mat of variegated colored tileswhich consists of the steps of establishing a variable-widthstrip-spacing reference grid, cutting rectangular panels of variouscolors into a first series of strips, locating said first series in ahorizontal plane according to the spacings defined by saidvariable-width grid, uniting said first series by a flexibleintermediate backing applied to the back face thereof, establishing anequal-width strip-spacing reference grid, cutting said first seriescross-wise of the strips therein into a second series of tilebearingrows, locating rows from the first series according to spacings of saidequal-width reference grid with alternate rows reversed end for end toeffect a staggered relation of the side marginal joints intermediate thetiles in alternate rows in respect to the tiles in the rows nextadjacent thereto, all said rows being in a common horizontal plane withtheir intermediate backing up, and uniting said rows by a commonflexible primary backing applied to the back faces thereof.

References Cited in the file of this patent UNITED STATES PATENTS NumberName Date 702,328 Parker June 10, 1902 1,133,604 Alcan Mar. 30, 19151,930,740 Desagnat Oct. 17, 1933

